Device and method for assembling capsules for extracting beverages

ABSTRACT

A method for assembling capsules for extracting beverages, the capsules including at least one main body for containing extract of a beverage, a filtering element positioned inside the main body and a base element positioned at the base of the main body; the main body, the filtering element and the base element forming at least partly the components of the capsule;
     the device includes a line for feeding the above-mentioned components and means for positioning the above-mentioned components along the feed line; more specifically, the feed line includes a conveyor, which moves continuously, forming a path for feeding the above-mentioned components and the positioning means are synchronised with the conveyor for assembling together the components on the conveyor.

TECHNICAL FIELD

This invention relates to a device and a method for assembling thecapsules for extracting beverages.

More specifically, this invention relates to disposable capsules forextracting beverages such as, for example, coffee, tea, milk or thelike.

BACKGROUND ART

The capsules comprise a main body for containing the product or aromaticsubstance, such as ground coffee or other products in powder form suchas milk or tea, from which the beverage is derived.

The main body is equipped with a chamber for containing the aromaticsubstance having an inlet opening through which the aromatic substanceis inserted.

The inlet opening may be sealed using a closing element in the form of acap or sheet of metal material, such as, for example, aluminium.

The capsules of the above-mentioned type comprise at least one filterlocated inside the product containment chamber and a base elementcoupled with the main body.

The capsules of the above mentioned type are obtained by assembling thecomponent parts, such a the main body, the filter and the base element.

There are prior art assembly devices comprising a line for feeding aplurality of trays each of which has a plurality of recesses positionedaccording to a plurality of rows parallel to each other.

The device comprises a plurality of stations for feeding respectivecomponents, such as the main body, the filter and the base element, bywhich the feed line conveys the trays for making the capsule.

The feed stations are located along the feed line according to thesequence for stacking the components forming the capsule, in particular,the base element is fed from the respective station, then the main body,which is positioned on the base element, and then the filter, which isinserted inside the main body.

The above-mentioned components are fed by “pick and place” robots which,however, have low production speeds of the prior at assembling device.

DISCLOSURE OF THE INVENTION

The aim of this invention is to provide a device and a method forassembling capsules for extracting a beverage which has a greaterproduction speed compared with the prior art, as described in theindependent claims 1 and 11.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is described below with reference to the accompanyingdrawings, which illustrate a non-limiting embodiment and in which:

FIG. 1 is a schematic perspective view of the device for assemblingcapsules for extracting beverages according to this invention;

FIG. 2 is a scaled-up schematic perspective view of a first detail ofthe device illustrated in FIG. 1;

FIG. 3 is a scaled-up view of a detail of FIG. 2;

FIG. 4 is a scaled-up schematic perspective view of a second detail ofthe device illustrated in FIG. 1;

FIG. 5 is a scaled-up schematic perspective view of a third detail ofthe device illustrated in FIG. 1;

FIG. 6 is a scaled-up view of a detail of FIG. 5;

FIG. 7 is a further scaled-up view of a detail of FIG. 5;

FIG. 8 is a scaled-up schematic perspective view of a fourth detail ofthe device illustrated in FIG. 1;

FIG. 9 is a scaled-up schematic perspective view of a fifth detail ofthe device illustrated in FIG. 1;

FIGS. 10 and 11 are schematic perspective views of respective details ofFIG. 8 during the step of rejecting the capsules.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

The numeral 1 denotes a device for assembling capsules for extractingbeverages, such as coffee, tea, milk or the like.

Each capsule 2 comprises at least one main body 3 containing an aromaticsubstance from which the beverage is extracted, the main body 3 having abase 3 b.

The capsule 2 comprises a filtering element 4 positioned at the base 3 bof the main body 3.

The main body 3, the filtering element 4 and the base element 5 defineat least partly the main components 3, 4, 5 of the capsule 2.

The main body 3 has a chamber 6 for containing the product or extractprovided with an inlet opening 3 a through which the product or aromaticsubstance is inserted inside.

The chamber 6 of the main body 3 is designed to contain, for example,ground coffee or other products in powder form such as, for example,milk or tea.

Preferably, the inlet opening 3 a is sealed using a closing element inthe form, for example, of a cap or sheet of metal material, such as, forexample, aluminium.

In use, hot liquid is injected inside the capsule 2, in particularinside the main body 3 through the inlet opening 3 a. The liquid passesthrough the chamber 6 containing the aromatic substance which, byinfusion, becomes a beverage which is extracted from the base 3 b of themain body 3, after passing through the filtering element.

In the preferred embodiment, the capsule 2 comprises a base element 5located at the base of the main body 3.

The base element 5 can form the dispenser of the beverage extracted fromthe main body 3.

Alternatively, the base element 5 can form an element for filtering thebeverage.

With reference to FIG. 1, the device comprises a line 7 for feeding theabove-mentioned components 3, 4, 5 and means 8 for positioning theabove-mentioned components 3, 4, 5 along the feed line 7.

The feed line 7 comprises a conveyor 9, which moves continuously,forming a path P for feeding the above-mentioned components 3, 4, 5.

The path P defined by the conveyor is a closed path, preferably in theshape of a ring.

Along the feed line 7 there are a plurality of stations 10, 11, 12 forfeeding, respectively, the main body 3, the filtering element 4 and thebase element 5.

More specifically and preferably, the station 10 for feeding the mainbody 3 is positioned upstream of the station 12 for feeding the baseelement 5, according to the feed direction of the conveyor 9.

The station 11 for feeding the filtering element 4 is positioneddownstream of the station 10 for feeding the main body 3 and the station12 for feeding the base element 5, according to the feed direction ofthe conveyor 9.

In other words, in the preferred embodiment illustrated, the station 12for feeding the base element 5 is positioned between the station 10 forfeeding the main body 3 and the station 11 for feeding the filteringelement 4.

As illustrated in FIGS. 2 and 4, the stations 10, 11, 12 for feeding themain body 3 and the base element 5 feed the respective components to theconveyor 9.

The device 1 has an outfeed station 16 at which the capsules 2, obtainedfrom the assembly of the main body 3 with the filtering element 4 andthe base element 5, are released.

More specifically, the feed line 7 comprises a first assembly station 14at which the main bodies 3 are assembled with the respective baseelements 5 and a second assembly station 15, positioned downstream ofthe first assembly station 14, at which the filtering elements 4 areassembled with the respective main bodies 3.

More specifically, the path P comprises at least one first section T1along which the conveyor 9 moves forward solely the main bodies 3 and asecond section T2, positioned downstream of the first section T1, alongwhich the conveyor 9 moves forward only the base elements 5.

The first section T1 extends from the station 10 for feeding the mainbody 3 to the station 12 for feeding the base element 5.

The second section T2 extends from the station 12 for feeding the baseelement 5 to the first assembly station 14.

The path P also comprises a third section T3, positioned downstream ofthe second section T2, along which the conveyor 9 feeds the baseelements 5 assembled with a respective main body 3.

The third section T3 extends from the first assembly station 14 to thesecond assembly station 15.

The path P comprises a fourth section T4 along which the filteringelement 4 is inserted in the main body 3, which is, in particular,assembled with the respective base element 5.

The third section T4 extends from the second assembly station 15 to theoutfeed station 16.

The conveyor 9 comprises a plurality of recesses 13 for housing at leastone of the components 3, 5 which are positioned one after the other todefine a single row. The housing recesses 13 convey the components 3, 4,5 of the capsule 2 along the path P towards the outfeed station 16,passing through the above-mentioned stations 10, 11, 12 for feeding themain body 3, the filtering element 4 and the base element 5 and throughthe first and second assembly stations 14, 15.

Advantageously, the positioning means 8 are synchronized with theconveyor 9 for assembling together the above-mentioned components 3, 4,5 on the conveyor 9.

The positioning means 8 comprise first means 17 for transferring themain bodies 3 and second means 22 for transferring the filteringelements 4, operating along respective sections of the path P in commonwith the conveyor 9.

The positioning means 8 move forward along at least one section of thepath P in common with the conveyor 9.

More specifically, along the above-mentioned sections of the path P incommon with the conveyor 9, the first and second transfer means 17, 22move forward, respectively, the main bodies 3 and the filtering elements4 and simultaneously the conveyor 9 moves forward the base elements 5.

More specifically, along the second section T2 of the path P, the firsttransfer means 17 hold the main bodies 3 raised above the respectivebase elements 5 with which they are assembled.

In practice, the first transfer means 17 pick up the respective mainbodies 3 from the first section T1 of the path P, keeping them raisedalong the second section T2 of the path P and release the main bodies 3on the respective base elements 5 along the third section T3, assemblingthem.

Generally speaking, the first transfer means 17 pick up the main bodies3 from the first section T1 of the path P to place them along the thirdsection T3 of the path P.

The first transfer means 17 pick up the main bodies 3, which are fedfrom the respective feed station 10, from the conveyor 9 to free therespective recesses 13 of the first section T1 of the path P, in such away that they are free to receive the base elements 5 fed from therespective feed station 12 at the second section T2.

The first transfer means 17 are connected by a kinematic mechanism withthe conveyor 9 in such a way that each seat 13 of the conveyor 9corresponds to a transfer means 17.

The first transfer means 17 are supported and rotated by a carousel 18rotating about its vertical axis 18 a.

The first transfer means 17 rotate about the vertical axis 18 a in thesame direction as the feed direction of the conveyor 9.

Cam means, not illustrated, allow the raising and lowering of the firsttransfer means 17 during their rotation about the vertical axis 18 a ofthe carousel 18.

Each transfer means 17 comprises a piston 19 movable along a directionparallel to its own vertical axis 19 a.

More specifically, the piston 19 translates along its vertical axis 19 aaway from and towards the conveyor 9 for raising and lowering the mainbodies 3 relative to the base elements 5 housed in the respectiverecesses 13 of the conveyor 9.

Each piston 19 comprises a relative head 20 equipped with elements 21for engaging with a respective main body 3 which activate in order toretain the main body 3 and they deactivate to release it.

Preferably, the engagement elements 21 can be extracted from therespective head 20 in a direction at right angles to the axis 18 a ofthe piston 18.

The second transfer means 22 are positioned downstream of the firsttransfer means 17, in the direction of rotation of the conveyor 9.

The second transfer means 22 convey the filtering elements 4 from therespective feed station 11 to the second assembly station 15. Morespecifically, along part of the third section T3 of the path P, thesecond transfer means 22 hold the filtering elements 4 raised above therespective main bodies 3 with which they are assembled.

The second transfer means 22 are supported by a drum 25 rotating about avertical axis 22 a.

The second transfer means 22 rotate about the vertical axis 22 a in thesame direction as the feed direction of the conveyor 9.

The second transfer means 22 comprise a plurality of punches 23 rotatingabout the vertical axis 22 a.

The second transfer means 22 are connected by a kinematic mechanism withthe conveyor 9 in such a way that each seat 13 of the conveyor 9corresponds to a punch 23.

Each punch 23 retains a respective filtering element 4, preferably bysuction.

It should be noted that the first and second transfer means 17, 22 arepositioned on curvilinear sections of the path P.

In use, the conveyor 9 moves forward continuously and each seat 13 picksup a respective main body 3 from the respective feed station 10.

With reference to FIG. 2, the recesses 13 convey the respective mainbody from the feed station 10 towards the station 11 for feeding thefiltering element 4, moving along the first section T1 of the path P.

At the same time, the piston 19 positioned on the respective seat 13starts to move parallel to the respective axis 19 a towards the seat 13of the conveyor 9 and of the main body 3 positioned inside the seat 13,until the respective head 20 is positioned inside the chamber 6 of themain body 3, as illustrated in FIG. 3.

At this point, the engagement elements 21 are activated, which withdrawfrom the head 20 until engaging with the walls of the chamber 6 of themain body 3.

Once the engagement elements 21 are holding the main body, the piston 19starts to move parallel to the respective axis 19 a away from the seat13 of the conveyor 9, raising the main body 3, freeing the respectiveseat 13.

The seat 13 is now be free to accommodate a respective base element 5fed from the respective feed station 12.

As shown in FIG. 4, the free seat 13 picks up a respective base element5 from the respective feed station 10 and starts to moves along thesecond section T2 of the path P.

Along the second section T2 the piston 19 located at the respective seat13 keeps the main body 3 raised above the base element 5 housed in theabove-mentioned seat 13.

As illustrated in FIG. 5, before the seat 13 reaches the first assemblystation 14, the piston 19 starts again to move parallel to therespective axis 19 a, carrying the main body 3 towards the seat 13 ofthe conveyor 9 and of the base element 5 positioned inside the seat 13.

At the first assembly station 14, with reference to FIG. 6, the piston19 positions the main body 3 on the base element 5 and imparts a slightpressure on the main body 3, using the relative head 20, so that themain body 3 and the base element 5 assemble in a snap-on fashion.

Downstream of the first assembly station 14, each seat 13 conveys arespective base element 5 assembled to the main body 3 along the thirdsection T3 of the path P.

At this point, the engagement elements 21 of each piston 19 withdrawdisengaging the respective main body 3.

Next, each piston 19 starts to move parallel to the respective axis 19 aaway from the respective seat 13 of the conveyor 9, until the head 20 ispositioned outside the respective main body 3, as shown in FIG. 7.

The piston 19, by the rotation of the carousel 18, passes from the thirdsection T3 of the path P to the first section T1 of the path P to startagain the operations described above.

It should be noted that to pass from the third section T3 to the firstsection T1, each piston 19 is rotated about the axis 18 a outside thepath P of the conveyor 9.

The recesses 13 of the conveyor 9 transfer the base elements 5 from thefirst assembly station 14 towards the second assembly station 15.

Upstream of the second assembly station 15, the second transfer means 22move along part of the section T3 of the path P shared with the conveyor9.

More specifically, while the recesses 13 of the conveyor 9 reach thesecond assembly station 15, each punch 23 picks up a respectivefiltering element 4 and conveys it to the second assembly station 15, asshown in FIG. 8.

More specifically, along part of the section T3 of the path P, eachpunch 23 is moved towards the respective seat 13 of the conveyor 9 forinserting the respective filtering element inside the main body, inparticular inside the chamber 6.

At the second assembly station 15, with reference to FIG. 9, the piston23 positions the respective filtering element 4 in the main body 3 andimparts a slight pressure on the filtering element 4 so that thefiltering element 4 is inserted in the main body 3 in a snap-on fashion.

Downstream of the second assembly station 15, the recesses 13 move alongthe fourth section T4 of the path P to the outfeed station 16.

More specifically, each seat 13 houses a capsule 2, comprising a baseelement 5, a main body 3 and a filtering element 3 assembled together.

At this point, each punch 23 moves away from the respective seat 13 ofthe conveyor 9, until it is positioned outside the respective main body3.

Once the punch 23 is positioned outside the respective main body 3 itreaches the station 11 for feeding the filtering element 4 by rotationof the vertical axis 22 a to start again the operations described above.

The recesses 13 convey the respective capsules 2 to the outfeed station16 at which they are expelled from the respective seat 13, freeing it.

FIGS. 10 and 11 show the outfeed station 16 of the conveyor 9 at whichthe device 1 comprises a gate 24 normally positioned in a closedcondition, to facilitate expulsion of the capsules 2 from the respectiveseat 13.

The gate 24 moves from the closed position to an open position to allowrejection of capsules 2 detected as defective.

More specifically, downstream of the second assembly station 15, thedevice 1 comprises a unit, not illustrated, preferably of an optic type,for controlling the completed capsules 2, which is able to detect thedefective capsules 2 to be rejected.

The control unit, not illustrated, is logically connected to a commandand control unit, not illustrated, logically connected to the gate 24for controlling the opening once the capsule 2, considered as defectiveby the control unit, reaches the outfeed station 16.

The defective capsule 2 continues along the path P of the conveyor 9drawn by the respective seat 13 and is expelled from the seat 13downstream of the outfeed station 16 at a reject station, notillustrated.

The reject station, not illustrated, is positioned upstream of thestations 10, 12 for feeding the main body 3 and the base element 5,respectively, according to the feed direction of the conveyor 9.

This invention also relates to a method for assembling the capsules forextracting beverages.

The method comprises a step of moving forward the above-mentionedcomponents 3, 4, 5 along a path P and a step of mutually positioningwith each other the above-mentioned components 3, 4, 5 during the stepof moving forward the components 3, 4, 5.

More specifically and advantageously, the step of moving forward thecomponents 3, 4, 5 is performed continuously along the path P and thestep of positioning the components 3, 4, 5 is synchronised with the stepof moving forward for assembling together the components 3, 4, 5 alongthe path P.

The step of positioning the components 3, 4, 5 comprises a step ofkeeping raised the main bodies 3 on the respective base elements 5during the step of moving forward the components 3, 4, 5 along the pathP.

The step of positioning the components 3, 4, 5 comprises a step ofkeeping raised the filtering elements 4 on the respective main bodies 3during the step of moving forward the components 3, 4, 5 along the path.

In the preferred embodiment, the step of moving forward theabove-mentioned components 3, 4, 5 comprises a first step of movingforward solely the main bodies 3 along a first section T1 of the path P,a second step of moving forward solely the base elements 5 along asecond section T2 of the path P and a third step of moving forward thebase elements 5 assembled with a respective main body 3 along a thirdsection T3 of the path P.

More specifically, the step of transferring the main bodies 3 from thefirst section T1 of the path P to the third section T3 of the path P.

The step of transferring the main bodies 3 comprises a step of freeingthe second section T2 of the path from the main bodies 3 for receivingthe base elements 5.

Advantageously, the device 1 according to the invention reachesproduction speeds greater than those of the prior art due to thecontinuous motion of the conveyor 9 and the synchronisation of the firstand second transfer means 17, 22 with the conveyor 9.

In a variant embodiment of the device 1, the pistons 19 of the firsttransfer means 17 pick up the main bodies 3 from the respective feedstation 10 in a position already raised relative to the seats 13 of theconveyor 9.

It should be noted, lastly, that in a first variant embodiment notillustrated, the device 1 comprises the station 11 for feeding thefiltering elements 4 positioned between the station 10 for feeding themain body 3 and the station 12 for feeding the filtering element 5.

In this alternative embodiment not illustrated, the second transfermeans 22 are positioned upstream of the first transfer means 17,according to the feed direction of the conveyor 9, for inserting insidethe main bodies 3 the respective filtering elements 4 and, subsequently,placing the main body 3, housing inside the filtering element 4, on therespective base element 5.

1. A device for assembling capsules for extracting beverages, thecapsules comprising at least one main body for containing an aromaticsubstance from which the beverage is extracted having a base and afiltering element positioned at the base of the main body and/or a baseelement positioned at the base of the main body; the main body, thefiltering element and/or the base element forming at least partly thecomponents of the capsule, the device comprising a line for feeding theabove-mentioned components and means for positioning the above-mentionedcomponents along the feed line; the device being characterised in thatthe feed line comprises a conveyor, which moves continuously, forming apath for feeding the above-mentioned components and that the positioningmeans are synchronised with the conveyor for assembling together thecomponents on the conveyor.
 2. The device according to claim 1, whereinthe positioning means move forward along at least one section of thepath in common with the conveyor.
 3. The device according to claim 1,wherein the positioning means comprise first means for transferring themain bodies and second means for transferring the filtering elementsoperating along respective sections of the path in common with theconveyor.
 4. The device according to claim 3, wherein along theabove-mentioned sections of the path in common with the conveyor, thefirst transfer means move forward the main bodies and the secondtransfer means move forward the filtering elements and simultaneouslythe conveyor moves forward the base elements.
 5. The device according toclaim 3, wherein the path comprises at least one second section alongwhich the conveyor moves forward solely the base elements and a thirdsection, positioned downstream of the second section, along which theconveyor moves forward the base elements assembled with a respectivemain body; the first transfer means keeping raised the main bodies onthe respective base elements along the second section and positioningthe respective main bodies on the respective base elements along thethird section assembling them.
 6. The device according to claim 3,wherein the path comprises a fourth section, positioned downstream ofthe third section, along which the conveyor moves forward the mainbodies assembled with a respective filtering element; the secondtransfer means keeping raised the filtering elements on the respectivemain bodies along part of the third section and inserting the filteringelements inside the respective main bodies along the fourth sectionassembling them.
 7. The device according to claim 3, wherein the pathcomprises at least one first section, positioned upstream of the secondsection, along which the conveyor moves forward at least the mainbodies; the first transfer means freeing the conveyor of the main bodiesby lifting them.
 8. The device according to claim 7, wherein the firsttransfer means lift the respective main bodies from the first section ofthe path, retain the main bodies along the second section of the pathand position the respective main bodies on the respective base elementsalong the third section assembling them.
 9. The device according toclaim 1, wherein the first and second transfer means are positionedalong respective curvilinear sections of the path.
 10. The deviceaccording to claim 1, wherein the conveyor comprises a plurality ofseats for housing at least one of the components the seats of which arepositioned one after the other to form a single row.
 11. A method forassembling capsules for extracting beverages, the capsules comprising atleast one main body for containing an aromatic substance from which thebeverage is extracted having a base and a filtering element positionedat the base of the main body and/or a base element positioned at thebase of the main body; the main body, the filtering element and/or thebase element forming at least partly the components of the capsule; themethod comprising a step of moving forward the above-mentionedcomponents along a path and a step of mutually positioning with eachother the above-mentioned components during the step of moving forwardthe components; the method being characterised in that the step ofmoving forward the components is performed continuously along the pathand that the step of positioning the components is synchronised with thestep of moving forward for assembling together the components along thepath;
 12. The method according to claim 11, wherein the step ofpositioning the components comprises a step of keeping raised the mainbodies on the respective base elements during the step of moving forwardthe components.
 13. The method according to claim 11, wherein the stepof positioning the components comprises a step of keeping raised thefiltering elements on the respective main bodies during the step ofmoving forward the components.
 14. The method according to claim 11,wherein the step of moving forward the above-mentioned componentscomprises a first step of moving forward solely the main bodies along afirst section of the path, a second step of moving forward solely thebase elements along a second section of the path and a third step ofmoving forward the base elements assembled with a respective main bodyalong a third section of the path.
 15. The method according to claim 14,wherein it comprises a step of transferring the main bodies from thefirst section of the path to the third section of the path; the step oftransferring the main bodies comprising a step of freeing the secondsection of the path from the main bodies for receiving the baseelements.